Wall construction



Dec. 26, 1939. LEARY WALL CONSTRUCTION Filed Nov. 9, 1958 Patented Dec. 26,1939

UNITED STATES 2,184,353 wan. oonsmoo'rron Marshall L. Leary, Columbus, Ga" assignor to The Consolidated Expanded Metal Companies,

Wheeling, g'lnia W. Va., a corporation of West Vir- Y Application November 9, 1938, Serial No. 239,616

8 Claims. '(Cl. 72-46) This invention relates to wall construction, and particularly to the construction of lath and plaster walls. It relatesstill more particularly to a studless wall construction which can be manufactured at very low cost and with a minimum consumption of wall space. The invention further relates to a l ath and plaster wall construction having a single layer of vertically stifiened lath and a single mass of plaster supported thereby, the plaster extending outwardly substantially equidistantly 'at the opposed faces of the lath and being finished at both sides to provide a partition Wall.

The standard manner of making lath and plaster walls heretofore has been to erect studding, attach the lath to the studding and apply the plaster to the lath. This manner of constructing walls has been comparatively costly. The cost of the studding and of its erection is very substanter is laterally ofiset with respect to the center of gravity of the lath to which it is applied, this unbalance creating stresses in the wall construction tending to weaken it structurally.

25 .In one: well known type of wall construction employed where comparatively thin walls are desired, studding is erected, lath is attached to one faceonly of the studding and plaster is applied to both facesof the lath to make a partition wall.

30 The thickness of the plaster at the face of the lath lying against the studding is considerably greater than the thickness of the plaster at the face of the lath disposed away from the studding. At the face of the lath lying against the studding the plaster must be somewhat thicker than the transverse dimension of the studding in order to completely cover the studding. The layer of plaster over each stud at this face of the wall is quite thin, and, as the faces of the studs oifer little or no bond'for the plaster, cracking of the plaster over the studs frequently occurs. It has also been proposed to employ ordinary metal lath carried by supporting means atthe floor and ceiling and to apply plaster to both sides of suchlath to form a partition wall. However, this construction is highly disadvantageous the cost of the installation. Moreover, the finished partition is very flimsy and could only be u used in the'lowest quality type of construction;

tial. Moreover, the center of gravity of the plasg the use of this construction is limited also to comparatively low walls, as when it is attempted to be used for comparatively high walls the lack of vertical stiifness is too pronounced to enable plaster to be applied while maintaining the wall true.

- I have devised a wall construction obviating the disadvantages of lath and plaster walls of the types above mentioned. I use no studding and employ only a single layer of vertically stiffened lath whether the wall be for fur'ring or for a partition. When the wall is to be a partition wall plaster is applied to both faces of'the single layer of lath so that in the finished wall there is but a single mass of plaster in which the lath is embedded and the center of gravity of the plaster and the center of gravity of thelath are in the same vertical plane, eliminating the stresses due to the unbalance in walls constructed on studding as mentioned above. As the thickness of plaster at both faces of the lath is substantially equal, the likelihood of cracking of the plaster at either face of the wall due to uneven contraction upon drying is minimized.

' I preferably provide supporting means connected with the ceiling 'or with one or more ceiling beams or joists and connect the single layer of vertically stiffened lath with the supporting means at the upper portion of the lath, the lath extending downwardly toward the floor. I preferably provide means at the lower portion of the lath for maintaining it against lateral movement generally normal to the wall. Part of the load of the lath may be carried at the floor or base of the wall, although I prefer to carry at least a sub stantial portion of such load upon the supporting means adjacent the ceiling. For example, the upper portion of the lath may be wire tied to the supporting means adjacent the ceiling and the lower portion of the lath may rest upon the floor or the means provided to maintain the lower portion of the lath against lateral movement generally normal to' the wall or may be wire tied to such last mentioned means, whereby the load of the lath is taken partially at the ceiling and partially at the floor.

I preferably'employ sheet lath and I find that expanded metal rib lath is of particular advantage. One type of expanded metal rib lath is known as Bar-X rib lath and has spaced metal ribs extending parallel to the long dimensions of the diamonds of the expanded metal. Heretofore lath of this type has been installed with the ribs and the long dimensions of the diamonds extend- 111g horizontally to give horizontal stiffness to the 2 2,1s4,sos

structure, the studding having been relied upon for vertical stiffness. Indeed it has been customary in using any expanded metal lath to erect the lath with the long dimensions of the diamonds 5 extending horizontally. I have found, however,

that I can use expanded metal lath to advantage in my wall construction with the long dimensions of the diamonds extending vertically, and I prefer to use Bar-X rib lath with the long di- 10 mensions of the diamonds and the ribs extending vertically. The vertical ribs give the wall sufficient vertical stillness and in that respect structurally take the place of studding. While I regard the employement of rib lath with the ribs 15 extending vertically as highly desirable in my wall construction, I may in some cases employ expanded metal lath without ribs but with the long dimensions of the diamonds extending generally vertically, which provides for considerably 20 more vertical stiffness than when the long dimensions of the diamonds extend horizontally.

I prefer to employ expanded metal as the supporting means for the lath adjacent the celling. The expanded metal which I prefer to em- 88 ploy for this purpose is heavier than the ordinary expanded metal lath, and I find that Golding type expanded metal is ideally suited for the purpose. I preferably provide a strip of such expanded metal elongated parallel to the long 80 dimensions of the diamonds and bend such strip adjacent one long edge so as to provide a flange extending substantially at right angles to the body of the strip. This flange I preferably place against the ceiling or other overhead supporting structure with the body of the strip extending downwardly and I fasten the supporting means thus provided to the ceiling or over-.

head supporting structure in any convenient way. At the floor approximately beneath the overhead support I preferably provide a channel with its flanges extending downwardly and with spaced slots in its web, such slots providing vertical openings through the channel. I preferably provide rib lath with at least some of the ribs 4 projecting endwise beyond the body of the lath proper, the spacing of the ribs being the same as or a multiple of the spacing of the slots in the channel. The lath is set in p ace with the pro- I jecting rib ends or similar projections on the u: lath entering at least certain of the slots in the base channel, which has previously been fastened to thefloor or other base support, as for ex.- ample, by nails, and the u per portionof the lathis wired to the expanded metal supporting flmeans. Plaster is appl ed to this single ayer of lath at both faces thereof to complete the partition. If the wall is to be employed as furring plaster may be applied to only one face of the lath. The laster is also appl ed to the downard v project ng portion of the overhead expanded metal sup ort which itself acts in the nature of lath and also as a reinforcement, i'orm na a very strong structu e. The laster k ys the upper p rtion of the lath and the ex- 66 pended me al together.

Alternativel I may provide at the base of the' It ribs of the lath, if rib lath is employed, need project endwise beyond the body of the lath proper. This construction aifords a strong and permanent connection between the wall and the floor, adjacent where the wall is in use likely to' be subjected to the greatest transverse stresses. 5

other details, objects and advantages of the invention will become apparent as the following description of certain present preferred embodiments thereof proceeds.

In the accompanying drawing I have shown certain present preferred embodiments of the invention, in which Figure 1 is a face view of a portion of a partition in process of construction with sections Clflt away and with plaster applied to part there- 0 Figure 2 is a vertical transverse cross-sectional view through the partition shown in Figure 1;

Figure 3 is a top plan view of the positioning channel employed at the bottom of the partition; and

Figure 4 is a fragmentary vertical transverse cross-sectional view similar to Figure 2 through the lower portion of a modified form of partition whose upper portion may be similar to the upper portion of the partition shown in Figures 1 and 2.

Referring now more particularly to the drawing, reference numeral 2 designates generally the floor or other suitable base support for the so partition, and reference numeral 3 designates generally the ceiling or other suitable top sup port for the partition. Fastened to the top support 3 is a supporting member 4 for the lath employed in the partition, the member 4 being of as generally inverted L-shape in cross section, as shown in Figure 2. and being made of Golding type expanded metal with the long dimensions of the diamonds extending longitudinally of the supporting member. The supporting 40 member 4 is made by providing an elongated strip of expanded metal and bending a portion of the expanded metal at one of the long edges of the strip so as in effect to form a flange extend ng substantially at right angles to the remainder or body of the strip. The supporting member 4 is positioned with its flange against the top support 3 and is fastened thereto in any suitable manner, as, for example, by nails or screws 5 passing through the expanded metal mesh of the flange of the supporting member and entering the top support and having adjacent their heads metal plates I large enough so as not to pass through the openings in the expanded metal. The su portingmember 4 is thus fastened to the ceiling or top support with its main or body portion extending downwardly therefrom.

Positioned on the floor or base support with its lon itudinal center line approximately below, although sl htly to one side (as shown in Figure 2) of the downwardly extending port on of the su portin member 4. is a positioning member I in the form of a channel with its flanges extending downwardly andits web horizonta ly. 55 The web 8 of the channel I is provided with spaced elongated slots 9 which in the particular construction shown in the drawing are s aced apart on 3 /2" centers. The slots 9 may, however,

be more closely spaced to reduce the amount of lap at adjacent edges of the sheets of lath, and I have found that the spacing of the slots on 1 centers is very satisfactory. The positioning member I is fastened to the base support 2 by nails or screws ll passing through alternate slots 9, the remaining alternate slots being left completely open at the time 'of attachment of the positioning member to the base support.

I employ sheet lath of any suitable type, the

to the expanded metal lath so as to extend parallel to the long dimensions of the diamonds thereof and such rods are arranged in parallel relationship throughout the sheet of lath and are spaced apart on approximately 7" centers in the particular lath employed in the construction shown in the drawing. At one end only the rods I 2 extend somewhat beyond the expanded metal of the rib lath, as shown at l3.

The lath is applied with the long dimensions of the diamonds and the ribs extending substantially vertically. The vertical height of the expanded metal portion of the lath when so applied is predetermined so as to be slightly less than the vertical distance between the upper surface of the positioning member I and the downwardly facing surface of the top support 3, and the rods- 12 extend outwardly beyond the expanded metal a distance somewhat less than the vertical dimension of the positioning member I. When the lath is applied the projecting ends I3 of the rods l2 are inserted through the alternate elongated slots 9 in the positioning member 1 not having nails or screws l0 therein and the upper portion of the lath is made to lie snugly against the downwardly projecting portion of the supporting member 4 and is wired thereto at suitable intervals by wires l4. Adjacent sheets of lath preferably have their adjacent edges overlapped as shown at IS in Figure 1. The overlapped edges of the lath are also preferably tied together by wire ties l6. Thus the lath is supported in substantially vertical position and maintained both at its top and at its bottom against lateral displacement. The expanded metal portion of the lath may rest upon the upper surface of the positioning member 1 or upon the upper surfaces of the nails or screws ill passing therethrough, as the case may be, so that its load may be divided between the posi tioning member 1 and the supporting member 4. A small space I! is left between the top of the lath and the downwardly facing surface of the top support 3 to allow for variations in ce ling height and for easy erection. The ribs l2, which are fastened at their upper portions to the supporting member 4 and which are held against displacement normal to the wall at'their lower portions by the positioning member I, lend to the lath sufiicient vertical stiffness to'allow application of plaster by troweling without an'undesirable amount of bending.

When the lathing has been installed as above described plaster i8 is applied to it at both sides to form the finished partition as shown in Figure 2 and in the upper right-hand portion of Figure 1. Preferably the total thickness of the partition is in the neighborhood of 2", although it may be more or less. The plaster forms a single mass with its opposed faces equidistant from the plane of the lath. The plaster keys not only in the lath but in the expanded metal of the supporting member 4 as well and keys the lath and the supporting member together, thus producing a very strong structure. Also the expanded metal of the supporting member 4 serves as the lath at the very top of the partition opposite the space ll. There is shown in Figure 4 of the drawing a modified construction for the base of a partition. This construction is to all intents and purposes identical with the top of the construction shown in Figure 2 but inverted. The positioning member is shown in Figure 4 is a piece of expanded metal bent into generally L-shape with its short leg lying flush against the floor 20 and fastened thereto in any suitable manner, as, for example, by nails 2| passing through plates 22 to prevent the nail heads from passing through the relatively large openings of the expanded metal. The lath is shown at 23 and may be identical with the lath shown in Figures 1 and 2. The lath is wired to the positioning member I! by wire ties such as shown at 24. The plaster, which is applied to both faces of the lath, is shown at 25. The upper portion of the structure shown in Figure 4 is preferably the same as the upper portion of the structure shown in Figure 2. As will be seen from Figure 4, it is not necessary that the ribs of the lath extend below the body of the lathyand in this structure :hahribs are cut off flush with the bottom of the a The lath is laterally unsupported at its vertically central portion, which expression as used in the claims means that at its vertically central portion the lath has no external means of support other than the plaster. Of course the ribs forming a part of the lath affordsupport to it. In the claims reference to a single "layer" of lath means one installation of lath in a single wall as distinguished from a plurality of spaced apart installations in the same wall such as are customarily employed, for example, at opposite faces of studding in 4" partitions. The overlapped ends of the sheets of lath form portions of a single layer of lath, as the expression is used in the claims.

My partition may be erected at very low cost and by actual test has demonstrated remarkable strength and may be considered as competitive with solid 2" partitions employing channel studs, which is a standard building structure. The cost of the studding, the cost of erecting it and the cost of tying the latch to the studding are eliminated. The positioning of the lath in the center of the partition minimizes the likelihood of cracking of the plaster. The likelihood of rust streaks appearing at the wall surface due to inadequate covering of the lath or studding with plaster is obviated. The use of rib lath with the ribs extending vertically gives to the structure desirable vertical stiffness so as to enable application of the plaster without undesirable deformation of the lath and without necessitating backing up of the lath while plastering. The use of vertically stiffened lath also substantially eliminates any likelihood of cracking of the plaster. Due to the studless character of my wall construction the attachment of grounds is rendered comparatively simple, as it is not necessary to fit the ground blocks between studs. The absence of studs also greatly facilitates plastering, which can be done by wide uninterrupted sweeps of the trowel. My wall construction has soundproof characteristics due to the elimination of studs. The strength of my wall construction is astonishing considering its low cost and I have found it to be stronger than other constructions of the same general character but of considerably greater cost.

'While I have shown and described certain present' preferred embodiments of the invention, it is to be distinctly understood that the same is not limited theretobut may be otherwise variously embodied within the'scope oi the following claims.

I claim:

1. Astudless wall construction, comprising po- I sitionlng means, a single layer of vertically stii-' bythe lath.

i'ened sheet lath laterally externally unsupported at its vertically central portion positioned by said positioning means, and plaster or the like carried 2. Wall construction,

tending stiffening ribs supported at its upper portion by said supporting means and having its lower portion'maintained against lateral movement generally normal to the wall and laterally externally unsupported at its vertically central portion, and'plaster or the like carried by the lath. 3. Wall construction, comprising positioning means, lath having elongated stifiening-ribs therein arranged generally vertically totend to counteract-lateral bending of the wall and positioned by said positioning means, 'and plaster orthe like carried by the lath. 4. Wall construction, comprising positioning .means, expanded metal lath having 'stifiening means extending generally longitudinally of the diamonds thereof positioned by said positioning, means, the lath;being arranged with the stlflen ,ing means and thevlong dimensions oi the diacomprising supporting. means, sheet lath having generally vertically exalum monds ex ending generally vertically, and plaster or the 'like'carried by thelath.

'5. Wall construction, comprising supporting means, lath supported at its upper portion by said supporting means and having elongated stiflening means extending generally vertically, and plaster or the like carried by the lath.

I 6. Wall construction, comprising supporting means, reinforced sheet lath supported at its upper portion by said supporting means, a portion oi the reinforcing extending outwardly substantially beyon 'the margin of the sheet to assist in .-means connected with the ceiling, positioning means at the floor below the supporting means, vertically stiffened sheet lath connected with the supporting means-and having its lower portion p0- sitioned by the positioning means and laterally externally unsupported at its vertically central portion, and plaster or-the like carried by the lath.

- MARsHALLn-LEARY. 

